Flushbolt jig cutter



April 5, 1966 M. L. GAMES FLUSHBOLT JIG CUTTER Filed April 20, 1965 M R. w M

INVENTOR.

United States Patent 3,244,205 FLUSHBGLT JIG CUTTER Marsh Leland Games, 1545 S. 4th Ave., Los Angeles, Calif. 90019 Filed Apr. 20, 1965, Ser. No. 449,932 6 Claims. (Cl. 144-3) This invention relates to the hanging of doors. Particularly, it concerns the accurate straight drilling of the hole for a flushbolt. Flushbolts are that hardware installed to hold the inactive leaf of a pair of doors. Flushbolts are usually installed in both the top and bottom of such a door.

The boring of the hole for a flushbolt, and the routing for the face plate, has, before the present invention, been slow, difiicult work, requiring considerable skill. There is danger of ruining an expensive door. The boring bit may go through the side of the door. It may go out of line and cause extra work. The operation, done in the usual manner, may take an experienced door hanger forty-five minutes to an hour. The door hanger may use a power drill and place the drill bit about 4 down from either the top or bottom of the door, whichever the case may be. The door hanger bores as straight as possible, freehand. This hole must be drilled straight for twelve, eighteen, or twenty-four inches. These are the usual lengths of fiushbolts. The door hanger may do this with hand tools. No satisfactory tools or method existed before this invention for doing this job with power or hand tools.

For the face plate, the door hanger may have made a wooden guide or template. He could use a lock mortiser. It is not meant for this job, but, with great care, it can be used.

My invention is a jig and template combination. It includes a boring guide, insures a straight accurate hole for the flushbolt, and has a template guide to rout out for the face plate. The operation saves forty minutes or more. It is completely accurate.

FIG. 1 is a side view of an example of the jig. Both sides of the jig are the same.

FIG. 2 is a top plan view of the structure shown in FIG. 1.

FIG. 3 is a sectional view of a portion of the structure shown in FIG. 1, taken along the lines 33 of FIG. 1.

FIG. 4 is a cross sectional of the structure of FIG. 1 taken along the lines 4-4 of FIG. 1.

Referring now to the drawings in detail, as an example of the invention, the tool consists of eight parts. The drill and router shown in FIG. 1 are shown as they are used with the jig, but they are no part of the invention. Everything but drill and router are numbered in the description.

The casting 5 is the main body of the tool. It consists of two sides 6, and a top 7. The bottom is open to allow placing on the door 15. FIG. 3 shows the closed end 8 of the casting 5. This end 8 is closed except for a hole 9 for the drill bit 10 to pass through the drill guide tube 11. This tube 11 is secured to the casting 5 in line with the hole 9 and is parallel to the top 7.

FIG. 3 also shows a brace 12, which may be a part of the casting 5, and is numbered differently to show its function as a support or brace 12.

The drill tube 11 is brazed to both the casting 5 and the brace 12. The drill tube 11 has a centered bore 13 as shown in FIG. 3 and may be of steel.

On the top part 7 of the casting 5, which sets on the edge 14 of the door 15 when in use, is a slot 16. This is a slot 16 in the casting 5, which, in conjunction with a top guide 17, is centered on both tool and door. The top guide 17 is brazed to the top of casting 5. The router 3,244,205 Patented Apr. 5, 1966 as shown in FIG. 1 is not a part of the invention. The router blade, guided by the top guide 17, will cut out for the face plate. The slot 16 and the guide 17 are so placed that the blade will clear this part of the casting 5.

Each end of the guide 17 will furnish the cut for an end of a flushbolt plate. The end 18 nearest the drill tube 11 will be one end of a twelve inch flushbolt plate. The other end 19 of the guide 17 is for one end of a twenty-four inch flushbolt face plate, see FIG. 2.

The sets of holes 20, 21 in the sides of the guide 16 as shown in FIG. 2 and FIG. 4 are for stop pins 22, 23. There may be more holes than shown on example. These pins 22, 23 will space the several lengths of routed mortises. The three most common lengths are twelve,

eighteen, and twenty-four inch.

The pins 22, 23 that go through the holes 20, 21 are shown in detail in FIG. 4. The pins 22, 23 are similar to a cotter pin in that they are split in that part 24 that goes through the second hole 20 in the guide 17. After the pin 22 or 23 is in place, it will spread slightly because of a spring 25 near the end of the split portion 24 of the pin 22 or 23. The spring 25, tiny but strong, will be held in place by two tiny projections inside the spring 25. Projections are not shown because of their small size and their location inside the spring 25. These pins 22 and 23 may be of spring steel.

Shown in FIG. 1, FIG. 2 and FIG 4 are examples of the clamping bolts 26. They will hold the jig to the door 15. These bolts are shown in detail in FIG. 4. The holes for these bolts 26, through the casting 5, are reinforced at 27 as shown in FIG. 4. These bolts 26 are tapped through the casting 5 and the reinforcing 27.

At the end of these bolts 26 is a tip 28 of plastic or rubber. The tips 28 are shaped as shown on the left side of FIG. 4. These tips 28 are replaceable and are recessed slightly when not in use.

A machine screw 29 holds the plastic or rubber tip 28. It is tapped into the center of the bolt 26. This screw 29 is recessed slightly, and will not scratch the door 15. The screw 29 is shown on right side of FIG. 4.

To use this jig correctly, follow 'these instructions. Clamp the jig casting 5 firmly to the door 15 as shown in FIG. 1. According to the length of the flushbolt to be used, insert the pin or pins 20 and 21. Take a router as shown in FIG. 1 and cut out for the face plate to the desired depth. Then drill through the drill tube 11 into the door 15 until the bit 10 reaches the routed out cut out. Then remove jig and square up the face plate with a hand chisel. Finally, using a hand chisel, cut out for the small plate through which the flushbolt will go through at the bottom and top of the door. The entire operation will take about five minutes. If the door hanger always checks the length of the fiushbolts, there is no chance for an error.

The example shown in the drawings, is for all three sizes of fiushbolts. A smaller model for twelve inch bolts only may be made since this is the size most usually used. This smaller model will use fewer clamping bolts. It will not need any pins as the top guide will form the cut out for the face plate.

The example shown is for 1%" doors. may be made for other widths.

The example, shown in the drawing, shows bolts for clamping on both sides of the casting. In some models these bolts will only be on one side.

I claim:

1. Flushbolt installation jig combination comprising:

elongated body member having:

a template face plate portion adapted to be disposed in juxtaposed contact with the edge of a Other models door contiguously to one end thereof, said face plate portion having a'router guiding template pattern formed thereon corresponding to a desired flushbolt faceplate receiving mortise;

door end engaging stop carried by said body member at one end thereof for locating said template pattern along said door edge;

drill guide tube member affixed to said one end of said 'body member and extending outwardly therefrom and having its bore aligned parallel to said face plate portion for guiding an elongate drill bit into the end of said door parallel with its said edge; and clamping means carried by said body member for removably securing said combination to said door.

2. The invention according to claim 1, in which said face plate portion is a flat plate and said template pattern is a substantially rectangular opening therethrough.

3. The invention according to claim 2 which further includes a pair of raised elongated router guide shoulders ailixed to said flat plate along two parallel edges thereof parallel to said bore and to the length of said elongated body member.

4. The invention according to claim 3 which further includes at least one router stopping pin and in which said guide shoulders are provided with router stopping pin retaining openings for receiving and holding removably said at least one stopping pin, said openings being disposed in pairs, individual ones of which in one shoulder are in register with another opening in the other shoulder along a line parallel to said door edge and perpendicular to the thickness of said door.

5. The invention according to claim 4 in which said References Cited by the Examiner UNITED STATES PATENTS 6/1953 Sulc 7762 9/1959 Evans et al. 14474 DONALD R. SCI-IRAN, Primary Examiner. 

1. FLUSHBOLT INSTALLATION JIG COMBINATION COMPRISING: ELONGATED BODY MEMBER HAVING: A TEMPLATE FACE PLATE PORTION ADAPTED TO BE DISPOSED IN JUXTAPOSED CONTACT WITH THE EDGE OF A DOOR CONTIGUOUSLY TO ONE END THEREOF, SAID FACE PLATE PORTION HAVING A ROUTER GUIDING TEMPLATE PATTERN FORMED THEREON CORRESPONDING TO A DESIRED FLUSHBOLT FACEPLATE RECEIVING MORTISE; DOOR END ENGAGING STOP CARRIED BY SAID BODY MEMBER AT ONE END THEREOF FOR LOCATING SAID TEMPLATE PATTERN ALONG SAID DOOR EDGE; DRILL GUIDE TUBE MEMBER AFFIXED TO SAID ONE END OF SAID BODY MEMBER AND EXTENDING OUTWARDLY THEREFROM AND HAVING ITS BORE ALIGNED PARALLEL TO SAID FACE PLAT PORTION FOR GUIDING AN ELONGATE DRILL BIT INTO THE END OF SAID DOOR PARALLEL WITH ITS SAID BODY MEMBER FOR RECLAMPING MEANS CARRIED BY SAID BODY MEMBER FOR REMOVABLY SECURING SAID COMBINATION TO SAID DOOR. 